Shaped foot coverlet and method for its manufacture on circular stocking knitting machines

ABSTRACT

The present invention pertains to a knitted foot coverlet or protective stocking, having in an integral shape, a pocket ( 10 ) that is overlapped by an elastic border ( 11 ) intended to cover the heel of a foot, a tiptoe portion ( 15 ) to cover the tiptoe of the foot, middle zones ( 12, 13 ) to cover parts of the foot between the heel and the tiptoe. These include a middle section ( 12 ) of constant width, continuing to the pocket ( 10 ) of the heel and intended to cover the foot at the hollow as well as a knitted tubular portion ( 13 ) between the middle section and tiptoe, intended to cover a remaining part of the plantar aspect and at least a part of the dorsal aspect of the foot. The present invention also pertains to a method for manufacturing the article on a circular stocking knitting machine.

FIELD OF THE INVENTION

[0001] The present invention pertains to a knitted article in the formof a foot coverlet or protective stocking, as well as a method for thecomplete manufacture of such foot coverlet or protective stocking oncircular stocking knitting machines.

BACKGROUND OF THE INVENTION

[0002] Various ways of making knitted articles in the form of a footcoverlet or protective stocking have already become known. These itemsare manufactured according to various methods in the current state ofthe art. For example:

[0003] by means of assembly for stitching pre-cut pieces of fabric andthe subsequent addition of an upper elastic border also by means ofstitching;

[0004] obtaining the product from suitably cut stockings, removing theirleg portion, and finishing manually, adding an upper elastic border bystitching, around the opening for insertion of the foot.

[0005] However, with these methods the elastic, which is inserted bymeans of stitching, in addition to having a negative effect on theproduction cost, also poses problems of adaptation to the foot, andthus, of wearability of the manufactured article because the elastic maybecome bulky, irritating and more or less stretched out.

[0006] Such manufacture of a foot coverlet or protective stocking on acircular stocking knitting machine by means of knitting continuouslywith alternating rotary motion from one end to the other of the article,so as to form a sole with two opposite pockets and with an elasticborder knitted on it, which defines the opening for insertion of a foot,has also been proposed. Even though the proposed method makes itpossible to eliminate the insertion of an elastic and the problemsconnected therewith, it is not, however, without drawbacks andlimitations linked with the particular mode of knitting, which does notmake it possible to easily shape the manufactured article and alsoinvolves:

[0007] poor wearability of the foot coverlet or protective stocking,which has a limited portion of fabric that covers the upper part of thefoot and thus tends to fall or slip off;

[0008] difficulty, if not impossibility, of producing a foot coverlet orprotective stocking with the dimensions so as to satisfy therequirements of the sizes even for larger people;

[0009] impossibility of adding decorative elements, such as designs ortrademarks, which are to be provided directly on the stocking knittingmachine; with the prior art up to now, these elements could only be donewith an additional, subsequent operation;

[0010] impossibility of producing the protective stocking or footcoverlet in a fabric different from the satin-like knit, e.g., mesh knitor dropped-stitch knit or ribbed knit.

SUMMARY AND OBJECTS OF THE INVENTION

[0011] One object of the present invention is to find a solution for thedrawbacks and the limitations of the prior-art methods mentioned abovein the manufacture of a knitted foot coverlet or protective stocking.

[0012] Another object of the present invention is to make a footcoverlet or protective stocking that can be obtained on a circularstocking knitting machine, substantially completely, and can be easilyshaped during its manufacture and can be correctly adapted to the shapesand measurements of the feet for maximum wearability thereof.

[0013] Another object of the present invention is to provide a footcoverlet or a protective stocking that can also be obtained withdifferentiated knitted zones in order to improve the covering and theaeration of the foot and for a better aesthetic appearance of themanufactured article when worn.

[0014] Still another object of the present invention is to provide amethod for manufacturing a foot coverlet or protective stocking shapedcompletely directly on a circular stocking knitting machine to give it amaximum degree of wearability.

[0015] According to the invention, a knitted foot coverlet or protectivestocking is provided having in an integral shape, a pocket that isoverlapped by an elastic border intended to cover the heel of a foot, atiptoe portion to cover the tip area of the toe of the foot and middlezones to cover the parts of the foot between the heel and tiptoe. Themiddle zones comprise a middle section of constant width, continuing tothe pocket of the heel and intended to cover a part of the plantaraspect and the sides of the foot at the hollow of same, and a knittedtubular portion between said middle section and said tiptoe, intended tocover a remaining part of the plantar aspect and at least a part of thedorsal aspect of the foot.

[0016] According to another aspect of the invention, a method isprovided for manufacturing a knitted foot coverlet or protectivestocking on a circular stocking knitting machine. The machine isprovided having a cylinder with needles capable either of continuousrotary motion or of alternating rotary motion. A semiannular initialelastic border is formed followed by a pocket knitted with alternatingrotary motion with selectively controlled needles on one section of thecircumference of the cylinder. A middle section formed of knitted rowsof constant width are knitted with alternating rotary motion and withthe needles on at least half of the circumference of the cylinder. Aknitted tubular portion formed of knitted rows is knitted withcontinuous rotary motion with the needles on the entire circumference ofthe cylinder, with the inoperative needles on the cylinder during theknitting of the middle section being put into operation at the start ofthe tubular portion. A closed or open tiptoe portion is knittedaccording to a usual procedure, continuing to the tubular portion.

[0017] The various features of novelty which characterize the inventionare pointed out with particularity in the claims annexed to and forminga part of this disclosure. For a better understanding of the invention,its operating advantages and specific objects attained by its uses,reference is made to the accompanying drawings and descriptive matter inwhich a preferred embodiment of the invention is illustrated.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In the drawings:

[0019] The sole FIGURE shows an example of a foot coverlet or protectivestocking when worn.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0020] Referring to the drawings in particular, the foot coverlet orprotective stocking according to the invention comprises, in succession,from back to front and without an arrangement of continuity:

[0021] a pocket 10 formed of partial knitted rows starting from asemiannular border 11 and intended to cover the heel of a foot;

[0022] a middle section 12 of constant width, formed of partial knittedrows and intended to cover a part of the plantar aspect and the sides ofthe foot at the hollow;

[0023] a tubular knitted portion 13 formed of complete, i.e., closed,knitted rows, starting from an elastic border 14 and intended to cover aremaining part of the plantar aspect of the foot and at least a part ofthe dorsal aspect of the foot; and

[0024] a tiptoe portion 15 formed of partial knitted rows starting froma fore-tiptoe zone 16 and up to a reknitted section 17, which tiptoeportion is intended to cover the tiptoe of the foot.

[0025] The various zones or portions 10, 12, 13 and 15 of themanufactured article may all be made with the same type of stitch,usually a plain stitch or at least partially a terry switch. However,and more preferably if necessary, the middle section 12 and/or thetubular portion 13, at least in that part which covers the dorsal aspectof the foot, may be made with a different knit, e.g., a ribbed,dropped-stitch or other knit.

[0026] The manufactured article described above is manufacturedcompletely on a circular stocking knitting machine having aneedle-carrying cylinder capable either of continuous rotary motion orof alternating rotary motion and provided, usually, with one or morefeed and knit formation stations, as well as with means for selectivelycontrolling the needles that must operate or not operate.

[0027] More specifically, the manufactured article is made by initiallyproducing the semiannular border 11, making the cylinder rotate withalternating motion and using the needles only on one section of thecylinder. The border 11 is knitted by introducing an elastic yarn thereand with a selection of the operating needles, e.g., 3:1, to give theborder proper an appropriate elasticity.

[0028] The number of needles used in this phase may be equal to theneedles on half of the cylinder or more of the machine. The use of anumber of needles greater than those on half the cylinder may besignificant for obtaining a manufactured article that guarantees asuitable covering of the lateral parts of the foot.

[0029] Then the pocket-heel 10 is knitted with alternating motion andwith the usual decreases and increases, using the needles on the machineas needed and, at any rate, in the known manner.

[0030] At this point, alternating motion is continued, and the needleson one section of the cylinder are allowed to knit in each knitted rowso as to obtain a middle knitted section 12 of constant width and ofvariable length, with this depending on the number of alternating motionstrokes made by the machine. This section 12 may be manufactured byputting the needle-raising and needle-lowering pickers of the machineout of operation with suitable methods and using a machine provided withelectromechanical actuators for selecting the needles operating withalternating motion.

[0031] Once the middle section 12 is finished the needles present on thecylinder that have not been operating up to that point are also put intooperation and thus the knitting of the border 14 is started with all ofthe needles of the cylinder and with the cylinder actuated withcontinuous rotary motion. This border, single or double, may be producedusing various knit interweavings, i.e.:

[0032] plain stitch knit,

[0033] 1:1 rib knit or other selections,

[0034] dropped-stitch knit.

[0035] Simultaneously with the manufacture of the knitting, the machineprovides, according to a prior art, for the weaving or knitting in of anelastic yarn in the border 14. This elastic yarn may be woven or knittedin either by all the needles of the cylinder or only by some of themwith the result of creating an annular elastic strip all around themanufactured article on a level with the border 14 or an elastic stripwith partial angular extension.

[0036] The length in number of rows of the elastic strip or of theborder 14 can be easily varied and correlated with the number of knittedrows in which the elastic is knitted.

[0037] Once the border 14 is knitted, the machine is then prepared forthe production of the knitted tubular portion 13 also with continuousrotary motion.

[0038] From this point forward, the stocking knitting machine operatesexactly as though the article being produced were a normal stocking and,thus, then proceeds with the manufacture of the tubular portion 14 ofthe fore-tiptoe 16, of the tiptoe 15, as well as, if the machine inquestion is provided with a LIN-TOE® system, of the reknitted section17, in this manner bringing about the finished product in the form of afoot coverlet or protective stocking.

[0039] If the machine is not provided with the LIN-TOE® system, aprotective stocking or a foot coverlet that is open in the tiptoe, whichmay be, however, reknitted or stitched with the traditional systems,shall be produced.

[0040] Among the advantages deriving from the present invention, thefollowing can be mentioned:

[0041] the variability of the length of the parts 12 and 13, which thusmakes it possible to produce protective foot stockings or foot coverletsof any length and thus without any size limitation,

[0042] the variability of the length of the parts 12 and 13, which makesit possible, by modifying the relationship between them, to obtain afoot coverlet or protective stocking that fits the foot to a greater orlesser degree and therefore to control the wearability of themanufactured article so that it does not fall or slip off the foot;

[0043] the elastic border 14, which makes possible a perfect adherenceof the manufactured article even to the dorsal or upper part of thefoot;

[0044] since the part of the manufactured article that covers the footconsists of a tubular knit, it is possible, using the standard featuresof the stocking knitting machine, to insert therein decorations,trademarks or particular types of knit: mesh, dropped stitch, ribbed.This was not possible with the method of the prior art, with which theentire article was produced by alternating motion and, using this, anytrademarks, designs, etc. had to be added with subsequent knitting.

[0045] While specific embodiments of the invention have been shown anddescribed in detail to illustrate the application of the principles ofthe invention, it will be understood that the invention may be embodiedotherwise without departing from such principles.

What is claimed is:
 1. A knitted foot coverlet or protective stocking,comprising: an integrally shaped pocket that is overlapped by an elasticborder intended to cover the heel of a foot; a tiptoe portion intendedto cover the tiptoe of the foot; middle zones to cover the parts of thefoot between the heel and tiptoe, said middle zones including a middlesection of constant width continuing to said pocket, said middle sectionof constant width being intended to cover a part of the plantar aspectand the sides of the foot at the hollow of same, and a knitted tubularportion between said middle section and said tiptoe, said knittedtubular portion being intended to cover a remaining part of the plantaraspect and at least a part of the dorsal aspect of the foot.
 2. A footcoverlet or protective stocking in accordance with claim 1, wherein saidknitted tubular portion has an initial elastic border.
 3. A footcoverlet or protective stocking in accordance with the claim 2, whereinsaid initial elastic border has an angular width so as to extend on thedorsal aspect of the foot.
 4. A foot coverlet or protective stocking inaccordance with claim 2, wherein said initial elastic border is annularto extend all around the foot.
 5. A foot coverlet or protective stockingin accordance with claim 2, wherein said initial elastic border has alimited angular width.
 6. A foot coverlet or protective stocking inaccordance with claim 1, wherein said pocket for the heel, said middlesection, said knitted tubular portion and said tiptoe portion allconsist of a same knit type.
 7. A foot coverlet or protective stockingin accordance with claim 2, wherein said pocket for the heel, saidmiddle section, said knitted tubular portion and said tiptoe portion allconsist of a same knit type.
 8. A foot coverlet or protective stockingin accordance with claim 1, wherein said middle section and said knittedtubular portion consist of a different type of knit from that formingsaid pocket of the heel and said tiptoe portion.
 9. A foot coverlet orprotective stocking in accordance with claim 8, wherein said middlesection and said tubular portion are formed with a ribbed knit.
 9. Afoot coverlet or protective stocking in accordance with claim 8, whereinsaid middle section is formed with a ribbed knit and at least a part ofsaid tubular portion that covers said dorsal aspect of said foot isformed with a dropped-stitch, open or designed knit.
 10. A knitted footcoverlet or protective stocking, having in an integral shape a pocketthat is overlapped by an elastic border intended to cover the heel of afoot, a tiptoe portion to cover the tiptoe of the foot, middle zones tocover the parts of the foot between the heel and tiptoe, said middlezones comprising a middle section of constant width continuing to saidpocket of the heel and intended to cover a part of the plantar aspectand the sides of the foot at the hollow of same, and a knitted tubularportion between said middle section and said tiptoe, intended to cover aremaining part of the plantar aspect and at least a part of the dorsalaspect of the foot, said knitted tubular portion having an initialelastic border having an angular width so as to extend at least on thedorsal aspect of the foot.
 11. A method for manufacturing a knitted footcoverlet or protective stocking having in an integral shape a pocketthat is overlapped by an elastic border intended to cover the heel of afoot, a tiptoe portion to cover the tiptoe of the foot, middle zones tocover the parts of the foot between the heel and tiptoe, said middlezones comprising a middle section of constant width continuing to saidpocket of the heel and intended to cover a part of the plantar aspectand the sides of the foot at the hollow of same, and a knitted tubularportion between said middle section and said tiptoe, intended to cover aremaining part of the plantar aspect and at least a part of the dorsalaspect of the foot, said knitted tubular portion having an initialelastic border having an angular width so as to extend at least on thedorsal aspect of the foot, the method comprising the steps of: providinga circular stocking knitting machine having a cylinder with needlescapable either of continuous rotary motion or of alternating rotarymotion; knitting the semiannular initial elastic border followed by thepocket with alternating rotary motion with selectively controlledneedles on one section of the circumference of the cylinder; forming themiddle section of knitted rows of constant width knitted withalternating rotary motion and with the needles on at least half of thecircumference of the cylinder; forming the knitted tubular portion ofknitted rows knitted with continuous rotary motion with the needles onthe entire circumference of the cylinder, with the inoperative needleson the cylinder during the knitting of the middle section being put intooperation at the start of the tubular portion; forming the closed oropen tiptoe portion knitted according to a usual procedure, continuingto the tubular portion.
 12. A method in accordance with claim 11,wherein the knitted tubular portion is started after the manufacture ofthe middle section, with the elastic border at least in the partintended to cover the dorsal aspect of the foot.
 13. A method inaccordance with the claim 11, wherein the knitting corresponding to themiddle section and/or the tubular portion is of the same type or adifferent type from that forming the pocket of the heel and the tiptoe.14. A method in accordance with the claim 12, wherein the knittingcorresponding to the middle section and/or the tubular portion is of thesame type or a different type from that forming the pocket of the heeland the tiptoe.